PacDrive 3: 2012 The future of motion-centric machine automation

PacDrive 3: 2012 The future of motion-centric machine automation
PacDrive 3:
The future of motion-centric
machine automation
2012
Automation
Solutions
with
PacDrive 3…
…faster
time-to-market
for your machines
2
Contents
Table of Contents:
Comprehensive Solutions from Schneider Electric ................................... 4
Complete Solutions with PacDrive 3 .................................................................. 6
Groundbreaking Systems Engineering.............................................................. 8
PacDrive in Action ......................................................................................................... 12
Energy Savings ............................................................................................................... 16
Technology ....................................................................................................................... 18
Application Software ................................................................................................... 20
Tools ..................................................................................................................................... 24
Electronic Help Documentation ........................................................................... 38
Controls .............................................................................................................................. 40
Functional Safety............................................................................................................ 44
I/O Communication ..................................................................................................... 46
Servo Drives, Multi-axis Solutions ........................................................................ 48
Integrated Servo Drives ............................................................................................. 52
Servo Drives, Stand-alone Solutions .................................................................. 54
Servo Motors ................................................................................................................... 56
Robotics Solutions ........................................................................................................ 60
HMI ........................................................................................................................................ 66
Field Bus Devices .......................................................................................................... 68
Electrical Components .............................................................................................. 72
PacDrive 3 and the Competition .......................................................................... 74
3
Comprehensive, integrated solutions from Schneider Electric…
Your solutions partner
for your entire factory
Schneider Electric is a trusted, global provider of a full range of products and solutions
for energy distribution and management, building automation and installations, and
industrial automation. With more than 100,000 employees in over 100 countries, 207
production facilities, and more than 16,000 sales offices worldwide, Schneider Electric
can provide expert, on-site assistance in the design and development of automation
process systems, equipment manufacturing, and plant engineering.
System Software
System Software
System Software
System Software
System Software
System Software
System Software
sercos
Remote IO
PacDrive 3
LMC
Working in perfect harmony:
Together – PlantStruxure™, for automation of processing systems, and MachineStruxure™, for automation of
individual production machines – provide scalable, fully integrated solutions for your entire factory and production
lines. PacDrive 3 (in shaded area above) is the logic motion control solution for MachineStruxure.
4
Comprehensive, integrated solutions from Schneider Electric…
Fully Integrated Automation Solutions
Using its proven PlantStruxure™ and
MachineStruxure™ architectures,
Schneider Electric can leverage its
comprehensive product portfolio for
industrial automation to achieve a single,
fully integrated solution. Everything works
together smoothly because scalable control
technology provides flexible automation of
both individual machines and processing
systems. Each solution can be supplemented
by a wide range of Schneider Electric
products that improve performance and
increase efficiency at multiple levels – from
an entire factory to a single production line,
or individual machine.
Schneider Electric also supplies solutions for
the vertical integration of production
processes. SCADA and MES solutions by
Schneider Electric create a seamless
connection between production floor and
management systems. As a powerful,
PC-based control and monitoring system,
the scalable Vijeo Citect™ SCADA software
is suitable for a wide range of needs, from
small companies to large corporations with
highly complex processes and demanding
availability requirements. Additional software
systems enhance the range of solutions
available for processes at different levels of
the factory.
Schneider Electric provides a number of
products and solutions for power distribution
and conversion, for both primary and
secondary distribution. This includes wiring
and cabling technology, and switchgear
technology for supplying electrical power to
machines and production systems. The
company also has extensive expertise in the
areas of energy management and metering
technology, and has its own subsidiary for
building automation and safety technology.
HMI controllers
> More compact
ic lle r
Logntro
Co
n
tio lle r
Montro
Co
I ller
HMntro
Co
Motion controllers
> Higher performance
ve l l e r
Drintro
Co
Drive controllers
> Added efficiency
Logic controllers
> Increased flexibility
Different controllers,
one software:
SoMachine™ is your
engineering workbench
for Flexible Machine
Control
Flexible Machine Control with SoMachine™
The goal of shortening development times in
machinery and plant engineering was the
driving force behind Schneider Electric’s
creation of Flexible Machine Control. The
term Flexible Machine Control refers to a
concept that consolidates the various
mutually supplementing control platforms in
MachineStruxure under the umbrella of a
single software solution: SoMachine. Using
SoMachine, the entire range of controllers,
from simple drive-based controllers to
high-performance motion controllers, can be
programmed and put into operation using a
single engineering workbench. This concept
requires no new tools or training. And, it
allows users to perform engineering tasks in
the same familiar software environment,
regardless of the respective control platform.
Comprehensive software libraries with
tested Application Function Blocks provide
valuable support.
5
For production, packaging, material handling, and robotics…
Complete automation
solutions with PacDrive 3
SoMachine™
Motion
Ethernet, TCP/IP, OPC, FTP,
ftp, http,
HTTP, SMS, SMTP
PacDrive 3 LMC 101C, 201C, 300C, 400C, 600C
Logic Motion Controllers
Safe Logic Controller*
SLC x00
IT/COM
Logic Motion
Magelis™ HMI
SERCOS 3 + Integrated Safety*
Other field busses:
PROFIBUS™ DP, CANopen™, EtherNet/IP,
Profinet™, Modbus™
LXM 62 Multi-axes Servo Drives
+ Power Supply + ILM 62 CM
Stand-alone
Servo Drives
LXM 52
Distribution
Box
TM5 I/O
TeSys™
ILx
ATV312
SD3 28
BRS3
TM7
Remote I/O
TM7
Remote I/O
SH
SH
SH
Torque
Motor
Linear
Motor
ILM 62
Field Bus
Components
One integrated automation platform, one versatile automation bus
Based upon proven motion-logic technology,
the PacDrive 3 automation solution from
Schneider Electric unifies PLC, motion, and
robotics control functionality on a single
hardware platform. With its centralized
system architecture, PacDrive 3 is the ideal
solution for controlling a broad range of
servo-driven production and packaging
machines, as well as material handling
equipment and robotics – using fully integrated,
IEC 61131-3-compliant program structures.
Schneider Electric SERCOS 3 technology
enables the entire communication process
for PacDrive 3 automation solutions to flow
through a fully integrated, Ethernet-based
automation bus. PacDrive 3 system
components are part of a broad overall
portfolio that includes HMI, automation, and
electrical equipment, that together create
complete single-source solutions for
demanding machinery applications.
The foundation for fully
integrated solutions:
Interoperability between
PacDrive 3 and the
extensive portfolio of HMI
components, automation,
and electrical equipment,
allows users to create
single-source solutions.
* according to IEC 61508:1998, EN/ISO 13849-1:2008
6
For production, packaging, material handling, and robotics…
sercos
PacDrive 3
LMC
P4
D2
MAX R
Mechatronic
Components
PacDrive 3’s proven technology provides a flexible, robust hardware platform for
MachineStruxure’s logic motion automation solutions. As the new generation of the
successful PacDrive M System, PacDrive 3’s scalable controller performance allows
economical automation of applications – ranging from small systems with only a few
servo axes to high-performance solutions with up to 99 servo axes or 30 robots.
* according to IEC 61508:1998, EN/ISO 13849-1:2008
7
Groundbreaking Systems Engineering >
PacDrive 3:
Sustainable automation
solutions…with
lower engineering costs
For years, Schneider Electric has pursued a technological approach
designed to consistently reduce hardware and software complexity. Our
consistent objective has been to hold the line against rising engineering
costs for design, installation, and commissioning. PacDrive 3 technology
opens up new opportunities for achieving this goal, and also introduces
new approaches for long-term cost savings.
8
Groundbreaking Systems Engineering >
Higher performance
with increased scalability
The PacDrive 3 Controller from Schneider
Electric provides a wide range of scalable
performance for synchronized multi-axis
motion, PLC functionality, and robotic
control – on a single hardware platform –
for both complex and simple machine
configurations. Performance in the upper
end of the range is sufficient for up to 99
servo axes or 30 robots. At the lower end of
the range, new controllers for a maximum of
4 or 8 servo axes are designed for more
economical automation of simple machines.
This approach delivers fully integrated
control technology for both simple and highly
complex applications!
Fully integrated
Ethernet-based communication
With the addition of SERCOS 3, Schneider
Electric has created the first fully Ethernetbased communication solution for PacDrive
applications, enabling communication with
both drives and field devices. SERCOS 3
can also streamline the integration of safety
automation*, and is a true standard. It does
not rely upon a specific manufacturer, and
it’s one of the most powerful Ethernet-based
communication solutions currently on
the market.
* according to IEC 61508:1998, EN/ISO 13849-1:2008
9
Groundbreaking Systems Engineering >
Flexible Drive Design
by Schneider Electric
Innovative drive design allows flexible drive
architectures. A multi-axis system, in which
single and dual-axis servo drives are
connected to a shared power supply,
reduces costs and space requirements in
systems with more than four servo axes.
Pluggable interconnects and a quickconnect front-side bus also reduce
installation costs.
For compact applications with a small
number of servo axes, the newly developed
stand-alone servo drives offer a more
cost-efficient approach to automation.
10
Groundbreaking Systems Engineering >
SoMachine™ for your machine…
SoMachine Motion is the new software from
Schneider Electric for your entire engineering
process, including: commissioning of
PacDrive 3 and diagnostics. SoMachine
Motion includes tools for motion design and
drivetrain design (ECAM), program
development (EPAS with ETEST, Vijeo
Designer™), diagnostics, and data handling
(assistants) – all in a single package.
A Safety Editor has also been added for
safety automation* software development.
EDESIGN is a new type of graphic
structuring of machine functions –
to further simplify software engineering.
The latest programming standards
EPAS, SoMachine Motion’s central software
development tool, is based upon CoDeSys
V3, and offers groundbreaking potential in
object-oriented programming.
* according to IEC 61508:1998, EN/ISO 13849-1:2008
11
PacDrive 3: Proven, trusted technology
12
PacDrive 3: Proven, trusted technology
International
Acceptance
In the consumer goods, durable goods, and capital goods industries,
machine buyers are the primary decision-makers when it comes to
choosing the best automation systems for their production and packaging
machinery. PacDrive systems from Schneider Electric have built an
excellent reputation among many European and international machine
manufacturers with their…
Proven technology
PacDrive is a tested technology based upon
internationally accepted open IT standards that
conform with IEC… and has demonstrated its
capabilities extensively since its introduction in
1998. Already more than 55,000 machines
worldwide have been automated with PacDrive
systems. Schneider Electric is also wellregarded around the world, with a reputation
for long-term reliability.
Compliance with OMAC and Weihenstephan Standard
For international manufacturers of consumer
goods products, the OMAC User Group’s
PackML state machine plays an important role
in integrating production and packaging
machinery for production lines. The creators of
PacDrive 3 were active participants in OMAC
from the very beginning, and integrated the
OMAC guidelines into PacDrive.
The Weihenstephan standard of making
production data available to management
systems has become increasingly important
in the beverage industry. PacDrive provides
software Function Blocks for implementing
this standard.
Y
READ
13
PacDrive 3: Proven, trusted technology
At a glance:
LEDs and system
messages displayed in
plaintext often provide
crucial information
about error locations.
High availability thanks to effective diagnostic tools…
Maintaining equipment availability depends
on how quickly operators can localize
malfunctions and eliminate errors. PacDrive
controllers provide basic diagnostic
information in plaintext on an integrated
display. A free diagnostic tool is also
available for PacDrive users…both machine
builders and operators. Any improper
Simple servo drive
configuration:
Less mechanical effort,
no parameterization –
the centralized
controller automatically
configures servo drive
and motors by using
their electronic
name plates
14
operation can be traced, regardless of the
individual machine‘s diagnostic capabilities.
The diagnostic tool contains almost the
same functionalities as the programming
and commissioning tool for engineering,
without the risk of unintended changes
to the machine program.
Plug-and-play technology for fast
component replacement
The ability to easily replace the electronic
components responsible for improper
operation is just as important as a rapid
diagnosis of the improper operation itself.
PacDrive users can quickly change-out
servo drives or servo motors using the
system’s plug-and-play technology.
Parameterization of replacement
components via laptop or software
installation is unnecessary. The centralized
PacDrive controller detects the replacement
components or motors by their electronic
name plates, and configures them
automatically. There is also no need to
activate switches for the SERCOS or IP
address. The controller performs a firmware
check and updates when the equipment
is replaced.
PacDrive 3: Proven, trusted technology
Standards instead
of proprietary
control technology:
IEC 61131-3-compliant
programming languages
are familiar to technical
personnel, thus reducing
the need for timeconsuming training
sessions in proprietary
programming solutions
Faster training thanks to standardized programming
Consumer goods manufacturers are very
enthusiastic about the fully integrated IEC
61131-3-compliant program structure in
machines automated with PacDrive. These
companies generally have personnel who
are familiar with IEC programming, and can
handle retooling of lines or machine
adjustments internally. The proprietary,
manufacturer-specific programming
concepts so common in robot-assisted
machine designs, on the other hand,
demand intensive training. A training
program for PacDrive 3 is available, as well
as a migration seminar for the changeover
from PacDrive M to PacDrive 3. The new
PacDrive 3 training program will include
training modules on programming,
commissioning, and service, as well as
mechatronic design and robotics.
Remote maintenance options
Remote maintenance reduces travel costs
and increases availability by accelerating
response times. PacDrive provides the
interfaces and/or protocols needed for
remote maintenance via the Internet, modem,
and mobile telephony. Schneider Electric
provides advice and support to machine
users and machine builders for integration of
the most practical options – worldwide.
15
PacDrive 3: Saving energy…
Energy efficiency –
a selling point
with a future!
The consumer goods industry places a
premium on energy-efficient manufacturing
systems, with lower energy use proven to
reduce machine lifecycle costs. Another
important factor in the competition for
market share, is to be seen as a “green“
company. Environmental consciousness
is increasingly important to consumers.
Develop an energy-efficient production and
packaging system, and you too can benefit
from a greener image. Schneider Electric
makes it easy for you with PacDrive 3.
16
PacDrive 3: Saving energy
Efficient motor technology
from Schneider Electric…
Servo technology is one of the most efficient
ways of transforming electrical energy into
kinetic energy. Among industrial electrical
motors, the high efficiency of servo motors
makes statutory minimum efficiency levels a
non-issue. This is particularly true for
PacDrive servo motors. Whether you are
using standard servos or servos with an
integrated servo drive, all Schneider Electric
PacDrive 3 motors deliver high efficiency
and low inertial loads.
DC bus sharing and
energy recovery
DC bus sharing among servo drives is a
standard feature for PacDrive 3 LXM 62.
Thanks to the front-side quick-connect, no
additional installation is required to connect
to the bus. DC bus sharing is particularly
well suited for packaging machines with
servo drives that don’t all need power at the
same time. The generous storage capacity
in these servo drives and their power
supplies, optimizes the energy produced
during a process.
Automation with less heat…
without control cabinets
Like other electronic components, servo
drives in the control cabinet generate heat.
If the resulting heat exceeds permissible
levels, then the control cabinet needs to be
cooled, consuming precious energy.
Schneider Electric ILM servo motors – with
integrated drive electronics – require only a
shared power supply in the control cabinet.
This lowers heat in the control cabinet and
reduces the need for climate control.
Energy-optimized
motion design
Technically optimized motion sequences
require less power, put less stress on parts, and
can be executed with less energy. PacDrive
Tools create the basis for energy-optimized
motion design, which reduces the need for
braking energy. These tools offer various motion
rules for simulating different approaches, or
they can use blending functions to create ideal
pick-and-place paths for robots.
Save energy with the PacDrive 3
“intelligent line shaft“
When machine speeds increase, some
individual axis movements exceed their set
energy consumption limits. This circumstance
can’t be changed if the system uses an
electronic line shaft that rigidly synchronizes all
of the axes with the master. The alternative – the
PacDrive 3 “intelligent line shaft” – offers a new
approach. Here the virtual master can activate a
speed profile over the course of a machine
cycle, increasing speed only for portions of the
motion profile that do not involve critical
changes in energy consumption. The speed of
the critical individual axis movements, however,
is increased only up to a predefined limit.
17
Winning Technology: PacDrive 3
Logic motion control –
the key to standardized,
cost-effective solutions
For more than a decade, a central element in Schneider Electric’s PacDrive
technology has been the integration of motion, PLC, and IT functionalities
on one automation platform. This allows the creation of fully integrated
software structures that enable modular machine designs and help reduce
engineering time.
Centralized controllers for all
machine functions
Basis for simulation and
plug-and-play
PacDrive’s digital system architecture is
based upon the concept of a centralized
controller. Using an IEC 61131-3-compliant
machine program, a single processor
performs all control functions, from
Cartesian and robotic motion to temperature
regulation and machine logic. All of the
system functions run through the centralized
controller, from the Human/Machine
Interface to motion and device bus
communication, line synchronization,
and vertical integration.
The centralized PacDrive 3 controller
generates the motion data for all servo axes
in the system. It also stores all relevant
system data and equipment-specific
parameters. This centralized approach offers
significant benefits:
• Moves can be tested and simulated in
the controller without having to connect
real drives.
• The controller supports reliable
communication with every servo
axis,including process data and motor
status, which can be analyzed for
different purposes.
• Servo motors and drives can also be
automatically configured based upon
electronic ‘name plates.’ The controller
recognizes the motors and drives, and
can send the centrally stored parameters
to each device for easy commissioning
or replacement.
• Configuration of individual drives is a
thing of the past.
18
Winning Technology: PacDrive 3
Ethernet
PacDrive 3:
Scalable – from basic to
high performance
ERP Data
Centralized
machine
controller
Regardless of whether a system involves
one machine or an entire production line, a
single PacDrive 3 controller can control up to
99 servo axes or up to 30 robots. Even less
complex architectures can be automated
economically. The scalable controller
hardware also offers a solution for
applications with 4 or 8 axes. It can even be
used as a pure-play PLC or a data
concentrator to acquire production data from
a packaging line. Users can synchronize up
to 40 controllers in real time – a fully
integrated solution for entire production lines.
IT
PLC
Motion
Real-time line
synchronization
Setpoint position
Control info
Service data
Current position
Status info
Service Data
SERCOS automation bus
1
2
Motor
control
loops
Motor
control
loops
99
Motor
control
loops
A foundation for fully integrated
software designs
One of the major advantages of PacDrive’s
centralized controller designs, is a unified
software development environment, with
one programming tool to implement the
functionalities.There’s no need for additional
tools, some of which might be proprietary.
One tool, one programming standard, one
software structure: This is the key to the
ground-breaking approach of modular
engineering, in which mechatronic functions
are mapped on reusable software modules.
To counter the trend toward rising
engineering hours, pre-tested software
libraries minimize programming time and
ease the way for FDA validation based upon
cGMP/GAMP and CFR 21 Part 11.
Distributed
servo drives
19
PacDrive 3: Application Software
Solutions designed to
reduce engineering costs…
While the hardware design has to be correct, it‘s the software that really
makes a solution work…and companies often spend more on software than
on hardware. Schneider Electric‘s PacDrive 3 software concept provides
a clear response to this development: Machine functions that have been
mapped in standardized software modules and collected in software
libraries serve as tested, off-the-shelf software to shorten development
times and increase engineering quality. A universal program structure also
paves the way for modular, reusable machine programs.
20
PacDrive 3: Application Software
Two approaches designed to reduce engineering costs…
The Schneider Electric PacDrive 3 software concept offers two ways to reduce rising
engineering costs: Programs can be programmed either in the conventional way, using
Application Function Blocks (AFBs), or by using PacDrive’s pre-defined program structure and
Equipment Modules (EMs). The latter option further reduces programming work for the user.
The program structure also creates standardized modular software that improves the
reusability of machine modules.
Conventional Programming
conventional
Advanced Programming
advanced
PacDrive
Program Structure
User program
User program
EM
(Equipment module)
= AFB + Op-Mode + Diagn.
+ Error handling
AFB
AFB
(Application Function Block)
(Application Function Block)
PacDrive portion of the
pre-programmed application
System Functions
System Functions
User portion of the
pre-programmed application
Conventional programming with Function Blocks
PacDrive software libraries consist of Function Blocks (AFBs Application Function Blocks), which map a variety of motion, PLC,
visualization, and IT functionalities in pre-programmed software objects.
These range from universal AFBs, for generating axis movements in
positioning and movement functions – to temperature regulation
operations. These libraries also contain Function Blocks that can be
parameterized for complete mechatronic functional units, such as
robots, rolling and unrolling functions, flying shear, or film sealing units.
Significant reduction
in programming times
Higher software quality
with documented and
well-tested programs
Easier program
validation
IEC 61131-3
compliant AFBs
21
PacDrive 3: Application Software
Advanced programming with Equipment Modules and programming template…
PacDrive 3‘s predefined programming template is a universal, basic
machine program into which users can integrate their own software
components. The program’s basic functionalities are already in place,
including OMAC-compliant operating modes, diagnostic mechanisms,
and error handling and response. These can be adapted to the
individual application by configuring them as needed.
A machine‘s functionality can be mapped to the program by connecting
the Equipment Modules. Equipment Modules are the functional
equivalent of Application Function Blocks. AFBs become Equipment
Modules when they are supplemented with a standardized interface,
operating modes, and diagnostic functions, and sometimes with other
Equipment Modules as well. They can then be used within a
programming template to create a cohesive, well structured program.
Reduced
engineering times
Transparent, modular,
easy-to-use programs
Basis for creating
modular, customized
software libraries
Complete machine
functions can be stored
as reusable, standardized functions
Compliance with OMAC
and Weihenstephan
guidelines for machine
and line standardization
In addition to simple AFB functionalities, an Equipment Module also
includes interfaces that allow error handling, diagnostics, and
operating mode functions to be utilized. By subdividing the program
into Equipment Modules and providing flexible linking mechanisms,
the programming template permits users to separate and reuse entire
machine functions.
Equipment Modules can also
be individually adapted by
users, e.g. to incorporate
special know-how or to
distinguish their machine
programs from the
competition.
Transparent
representation
of the machine:
The modular program
consists of Equipment
Modules, whose
functions can be either
based on AFBs or
assembled using other
Equipment Modules.
Robot 1
Equipment Module Level 2
22
Robot 3
Infeed
Dual Belt
Conveyor Belt
Secondary Packaging
Machine Level
Equipment Module Level 1
Robot 2
Grouping
Infeed
Dual Belt
Cartoner
Robot 1
Robot 2
Robot 3
Conv. Belt
PacDrive 3: Application Software
Identical functions available as AFBs or Equipment Modules…
Software functions available for PacDrive 3 have been created as AFBs, or as corresponding
Equipment Modules.
The libraries contain most of the functionalities needed for forming, filling, and sealing
machines, dosers, cartoners, labelers, pick-and-place applications, and end-of-line
packaging machines. They also offer a variety of mechatronic functions typically used in
production machinery and in handling, assembly, and sorting systems.
Extensive Function Block libraries, including PLCopen
Enhanced software
quality thanks to off the-shelf software
(FDA, cGMP, 21CFR
Part 11)
The AFBs and EMs are documented and have been well-tested in practical use, a basic
requirement for high software quality, reduced engineering time, and rapid commissioning.
This also makes certification of machines and software much easier.
Application
Library
Individual machine
PD_Template.Lib
Function Blocks for operating mode management, control of state changes,
exception handling, error reaction, or predefined commissioning screens
Included Application Function Blocks (examples)
PLC Function Blocks
PacDrive.Lib
Standard PLC functions such as bit or conversion functions, shift register for
LREAL values with access functions, etc.
FieldbusDevices.Lib
System.Lib
Motion Function Blocks
Field bus diagnostic function blocks, Function Blocks for motor protection
switches or frequency converter, etc.
Event-driven adjustments of any number of cam switch groups
PacDriveLibModules.Lib
Universal axis AFB for homing, positioning, curve functionality, jogging, etc.
PacDrive.Lib
Safety*/Hardware, e.g.
Power on and power off of axes with monitoring functions, etc.
PacDrive.Lib
Axis and encoder positions, homing, positioning (automatic and manual), virtual
master axis control, minimization of mechanical wear and tear, increase of
machine speed, and reduction of energy usage with the ´Intelligent Line Shaft,´ etc.
Cam disk handling
PacDrive.Lib
Processing from table or modification of cam disk profiles on the fly, cold or warm
start functions, etc.
Mathematical functions
PacDrive.Lib
Matrix operations, vector and polynomial functions or functions for toggle
transformations, etc.
Technology functions
PacDrive.Lib and others
Torque handling
System.Lib
Speed-dependent torque limit (e.g. for bottle sealing equipment), etc.
Robotics
Robotic.Lib
Automatic path planning, path generation and optimization, transformation to
different kinematics, belt tracking, synchronization of robots, etc.
Infeed
MultiBelt.lib/-Module.lib
Control of dual-belt and multi-belt mechanisms for product grouping and infeed
Infeed
SmartInfeed.lib/-Module.lib
Control of serial conveyor belts as infeed lines, product detection, management,
and transfer, synchronization of conveyor belts, etc.
Standardization
ISA.Lib, Weihenstephan.Lib
Weihenstephan Standard, OMAC PackML FDA
HMI application
Vijeo Designer
Machine Pilot
programming
SoMachine™ Motion
™
PID controller, registration mark control, winding and unwinding with and without
dancer, sealing, etc.
Vector graphics for design, open source software, functions for machine
operation, including recipe handling, sample screens, simulation/teleservice,
also via Web servers, etc.
Universally adaptable sample programming template
Description of the most
important PacDrive
libraries, with examples
showing the scope of
function. The software
functions are available
as either AFBs or
Equipment Modules
* according to IEC 61508:1998, EN/ISO 13849-1:2008
23
Tools: SoMachine™ Motion Software
PacDrive 3 Tools:
Actively shaping
the modern
engineering process
To keep pace with increasingly complex machine functions and designs,
and the software and data that support them, engineers will have to rethink
their project processes and adopt new approaches. Schneider Electric’s
SoMachine Motion software is the engineering workbench for PacDrive 3
applications that can help actively shape the current transformation
in engineering.
24
24
Tools: SoMachine™ Motion Software
SoMachine™ Motion:
A workbench with all the
tools needed for the
engineering process,
and for service during
live operation
Intuitive user interface:
The tools are structured
based upon area of use
(upper left), and dedicated
icons allow users to orient
themselves easily within
the program
SoMachine Motion software Engineering Workbench
The SoMachine™ Motion workbench from
Schneider Electric consolidates – in a single
package – the tools needed for the entire
lifecycle of a PacDrive 3 solution. This “toolkit”
includes: tools for program development, HMI
applications, motion design, drivetrain design,
and data handling…and provides all the
functionalities needed for engineering and
commissioning. Users can use the integrated
help system when creating programs, and the
workbench’s integrated documentation can
answer questions about PacDrive 3 hardware
components. A powerful diagnostic tool
permits rapid analysis of detected problems
during production.
No need for folders full of CDs or optional
tools: The necessary tools are available once
SoMachine Motion is installed on the user‘s
Windows PC. Selected individual tools can
be installed for servicing or other purposes
that require only part of the program‘s total
functionality. For example, installation can
be limited to diagnostic functions for
servicing purposes.
25
Tools: SoMachine™ Motion Software
Multi-user design with a central database…
Schneider Electric SoMachine™ Motion
software stores all project data in a central
database (project file). This data is universally
accessible for all of the tools on the
workbench. This central storage of project
data forms the basis for SoMachine Motion’s
soon-to-be-released multi-user design –
Team A
One project,
multiple participants:
A central database and a
powerful multi-user design
will enable future users to
have simultaneous access
to software projects down
to the Function Block level
allowing an entire team to work concurrently
on the same software project, with
simultaneous access to AFBs (Application
Function Blocks) and motion profiles. This
reduces unwieldy version management
processes and coordination tasks, that can
slow down teamwork.
Project data
Team B
Project file – central data pool
Team D
Team C
Trusted open standards
Object-oriented programming:
EPAS, the programming tool for SoMachine Motion, is based upon CoDeSys V3
SoMachine Motion can be used to create
IEC 61131-3-compliant programs.
SoMachine Motion’s central software
development tool – EPAS – is based upon
CoDeSys V3, which offers the option of
either traditional or object-oriented
programming. Object-oriented programming
has been the de facto standard in embedded
and PC software development for years, and
has also been a central focus of technical
instruction at universities.
Continuity to preserve value
In addition to these new tools, Schneider Electric’s
SoMachine Motion also includes the proven
PacDrive M tools. Projects created for PacDrive M in
EPAS-4 can be converted for editing in SoMachine
Motion, and can be ported to PacDrive 3. This idea
of reducing engineering costs by producing modular,
reusable software continues in the next generation
of PacDrive.
26
Project conversion:
Software projects
created with EPAS-4
can be converted to
SoMachine Motion
Tools: SoMachine™ Motion Software
Building bridges between mechanics and software
In modern engineering, the areas of
mechanics and software are increasingly
involved in interdisciplinary collaboration.
As the need for this collaboration grows, it
requires tools to bridge these two disciplines.
Schneider Electric’s SoMachine™ Motion has
succeeded in building just such a bridge.
For example, electronic cam disks created
with graphic CAM can be edited with the
ECAM tool. With its emphasis on curve
design, drivetrain layout, and power
requirement calculation, this tool shares
many similarities with mechanical drive
design. Moreover, the same curves can also
be processed in EPAS, the programming tool
in SoMachine Motion. Both tools contain all of
the necessary data, parameters, and editing
functions, so that edits performed in EPAS
are then available in ECAM, and vice versa.
This establishes a functional interface
between both tools, which serves as a bridge
for interdisciplinary collaboration between
mechanical and software engineering.
Motion design in ECAM:
ECAM is the classic tool for
drivetrain design and power
requirement calculation
Motion design in EPAS:
The CoDeSys 3-based
programming environment
has been enhanced
with a plug-in that adds
functionalities for editing
electronic curves
27
Tools: EPAS Automation Toolkit
EPAS:
Uniform programming and parameterization
Configuration editor:
Hardware components and
field buses (PROFIBUS™ DP,
CANopen™, SERCOS 3)
can be configured and
parameterized in the editor
Trace Function:
The integrated oscilloscope
in EPAS permits simultaneous
plotting and display of
multiple PLC and motion
signals, as well as mixed
PLC and motion signals with
millisecond resolution
With its combination of advanced functionality
and proven software, the EPAS Automation
Toolkit from Schneider Electric is a powerful
programming tool for PacDrive applications.
EPAS can be run from SoMachine Motion,
and its interface has the look and feel of
typical Windows applications. EPAS’s easy
navigation between editors and within
libraries provides for ease of use and
transparency when creating and simulating
programs and commissioning. And, EPAS
functionality streamlines the engineering
28
process. With the integrated configuration
editor, a few entries are sufficient to
configure, parameterize, modify, or expand
the solution’s hardware components and
field buses – and EPAS’s customizable HMI
offers assistance when developing, testing,
and simulating the controller application.
Preprogrammed screens are already
available for the commissioning process,
while machine programs can be simulated
onscreen – in EPAS – without real drives.
Tools: EPAS Automation Toolkit
System check
of device configuration:
The nodes in the SERCOS
interface can be scanned,
resulting in a display with
status information on
each node
An eight-channel software oscilloscope
integrated into EPAS permits simultaneous
plotting of up to eight PLC and motion
variables (including mixed variables). During
commissioning, the tool’s message logger
makes it easy to track down the source of
system and user diagnostic messages.
EPAS Automation Toolkit can be used with
all models of the PacDrive 3 Controller.
No conversion is needed to download
programs to different controllers.
Ladder Diagram
Function Block
Instruction List
Structured Text
Sequential Function Chart
Continuous Function Chart
Programming in compliance
with IEC 61131-3:
EPAS includes editors and
debuggers for all six standard
IEC languages
Uniform programming and parameterization
Program simulation without real axes
Hardware configuration and parameterization without the need for additional editors
Visualization tool with pre-programmed commissioning and service screens
Simultaneous trace plotting of PLC and motion signals (software oscilloscope)
Diagnostic functions,
including message
logger
IEC 61131-3 editors
CoDeSys V3-based
29
Tools: EDESIGN Graphic Programming
EDESIGN:
A revolutionary new form of graphic
programming from Schneider Electric
Graphic programming:
A significant reduction of
programming complexity
shortens engineering times
At Schneider Electric, efforts to further reduce
programming complexity and an emphasis on
modular software are producing completely
new approaches for the creation of machine
programs. The result is EDESIGN.
Using a structure editor that allows easy
assembly of a complete machine, using a
drag-and-drop function to select predefined
modules…together with other editors using
command lists to define operating modes
and state diagrams…EDESIGN tools
provide virtual graphic programming. With
commissioning and debugging being
performed directly in these editors, exception
30
handling and operating mode management
is radically simplified.
The results are clearly structured
configurations in which predefined modules,
e.g. a servo axis, can be configured with
easy dialogs. Movements can be integrated
directly from ECAM. And, hardware is
assigned to the modules by means of
selection fields with dialogs to assist
the user.
EDESIGN: Innovative simplicity for your
complex machine design.
Tools: ETEST
ETEST:
For developing and executing system tests of modular
machine programs…
Early detection of
software problems:
ETEST is the tool
for creating and
performing automated
software tests
PacDrive 3 libraries have AFBs (Application
Function Blocks) that can be parameterized
for a variety of mechatronic, mathematical,
and technical process functions. The ability
to create programs based upon years of
proven and documented off-the-shelf
software not only saves time, but also
significantly improves software quality. In
addition, Schneider Electric’s SoMachine™
Motion ETEST tool is used to develop and
execute system tests of modular machine
programs. By using test routines that
automatically test isolated software modules
within a program, software problems can be
identified, even at an early phase of the
project. These module tests are a valuable
component of the software validation process.
ETEST fully performs this valuable function.
31
Tools: SoSafe
SoSafe
Safety Editor* and Configurator
for safety automation…
IEC 61131-3-Editor:
The programming
languages Function
Block Diagram (FBD) and
Ladder Diagram (LD) can
be used to develop the
program code
The integration of safety automation into
standard automation is a critically important
user requirement. Schneider Electric’s
PacDrive 3 SoMachine™ Motion software
SoSafe includes an editor for safety
automation. And, the creation of IEC 611313-compliant programs for PacDrive safety
controllers is as integral to the workbench as
the parameterization of system component
safety functions. In addition to the program
editor, the SoSafe tool also has a
configuration editor that can be used to
parameterize components such as I/O
components or servo drives that are
integrated into the safety solution.
* according to IEC 61508:1998, EN/ISO 13849-1:2008
32
Tools: ECAM
ECAM
Motion and drivetrain design tool…from
Schneider Electric’s PacDrive 3 SoMachine Motion software
ECAM is a single tool that can be used to
design a complete system, from mechanics
and motion design to calculation of system
power requirements. To streamline the
engineering process, ECAM includes a library
of predefined standard mechanical drive
configurations, simplified motion design –
with a graphical motion profile editor – and
standard motion profiles.
This makes ECAM a functional tool for
mechanical engineers in designing and
selecting motors, gears, and power
components. Tools for calculating power
requirements and determining the energy
available from the DC bus also help in
developing energy-efficient machine designs.
A seamless, bidirectional interface allows
curve data and mechanical parameters to
be automatically provided to EPAS – the
SoMachine Motion programming tool. Data
can be adapted in EPAS and are then
immediately available again in ECAM – a
bridge between mechanics and software.
Drivetrain design:
Predefined applications
offer adaptability for
typical power transmission
configurations
Graphical motion design:
By cascading editor windows, users can place movement
patterns in chronological relationship to one another
Motion design with virtual or real master axes
Use of multi-segment profiles, such as VDI 2143 profiles or fifth order polynomials
Import of cam tables via Excel tables
Database for servo motor/drive and gear reduction sizing and selection
Predefined applications such as general loading condition, belt drive, spindle drive, rack-and-pinion drive, and crank drive
33
Tools: Vijeo Designer™
Vijeo Designer™
Customized design of Human/Machine Interfaces
Vijeo Designer:
A large number of
predefined elements,
graphics libraries, recipe
and alarm management
functions, and an easyto-modify suggested
schematic make HMI
development fast and easy.
One tool for all panels
Predefined functions
and graphic elements
provide design support
Fast solutions with
open-source sample
program
ARTI driver for browsing
control variables without
an OPC server
Open-source
software included:
A suggested schematic
diagram is easy to modify,
simplifies the learning
process for Vijeo Designer,
and produces fast results
Schneider Electric’s Vijeo Designer software
can be used to configure all Magelis™
touchscreen panels, from the smallest 3.8"
panel up to complex HMI applications for the
19" panels. This tool set also includes the
ARTI protocol driver that allows users to
access runtime system variables via the
browser. The tool’s graphical editor provides
a number of ready-made elements for
customizing HMI interfaces. And, the
graphics library has more than 4,000
predefined vector graphics. An integrated
34
recipe maintenance program manages 256
recipes with 1,024 ingredients in up to 32
recipe groups, and users can perform
periodic or event-driven processing of
Java-based procedures to automate
operations, including: switching screens,
performing mathematical and logical
calculations, and making automatic changes
in variables. Also, Vijeo Designer’s alarm
management system is designed for up to
9,999 alarms.
Tools: Controller Assistant and Drives Assistant
Controller Assistant and Drives Assistant
PacDrive 3 tools for data management
Schneider Electric’s PacDrive 3 support
tools make it easy for PacDrive users to
handle program and firmware data and to
perform program version management.
The Controller Assistant stores data and
files on the flash drive and creates a copy on
the user’s PC. If necessary, this copy can be
used to restore the program to original
status. The tool’s functions also include the
creation of CompactFlash cards for
PacDrive controllers (including bootable
cards). These cards include the VxWorks
operating system and firmware.
The Controller Assistant supports firmware
exchanged between PacDrive controllers via
Ethernet. If a user wants to check a network
for existing PacDrive controllers, the
Controller Assistant can identify connected
controllers and display their identifying data.
The Drives Assistant allows the
maintenance and exchange of firmware on
SERCOS nodes. Servo drives, bus
interfaces, and even TM5 I/O modules can
be easily supplied with new firmware from a
central location. The integrated management
of firmware versions optimizes their storage
and retrieval.
Data management:
Tools make it easier to
transfer and handle
program and firmware data.
This screenshot shows the
Controller Assistant
35
Tools: Diagnostics
Diagnostics
PacDrive 3 maintenance without EPAS
Diagnosis of
machine malfunctions:
Diagnostics can be used
to perform comprehensive
system diagnostics even
without programming
knowledge. The screenshot
shows a check of the PLC
configuration.
Simple tool for
collecting service-related
system data
No EPAS required
Firmware-independent
System map of servo
drive data (drives,
message loggers, cam switch group)
Intuitive user interface
System check:
Diagnostics can be used
to check the hardware
and software versions
of the servo drive
components on the PC
EPAS – SoMachine Motion’s programming
language – integrates comprehensive
diagnostic functionalities, but is not always
available if a machine breaks down during
production. This is why PacDrive Diagnostics
was developed specifically for use by
machine operators for servicing purposes.
This tool offers a full range of diagnostic
functions, runs independently of EPAS, and
is available at no cost to PacDrive users. It
also can be used without any programming
36
knowledge, since the intuitive program
interface allows users to quickly collect the
necessary servicing data. Diagnostic
information is displayed upon demand,
stored, or forwarded directly to technical
support, and the tool can be used regardless
of the firmware version.
37
Electronic Help Documentation >
PacDrive 3:
Complete online
documentation
Schneider Electric knows that even with intuitive tool interfaces, sometimes
you need help. From your first steps with SoMachine™ Motion to routine
project work…experience has shown that support is most useful when it is
available right on screen. In SoMachine Motion, “Guided Tours” familiarize
users with tools, while electronic documentation on tool and library
functions make printed manuals unnecessary.
Guided Tours through SoMachine Motion
Guided Tours – Help for beginners, including an interactive demo project
Keyword search in the documentation via the Index function
Search for topics using content directories
Extensive documentation
of library functions
Guided Tours are an easy way to learn how
to use SoMachine Motion. Each tour
addresses different topics and/or learning
objectives. The Guided Tours are listed in an
overview, and can be started from there.
Each tour completely covers a given topic
and consists of a number of easy-to-follow
(and illustrated) steps. Users can move back
and forth between the steps, and can
proceed through them at their own speed.
Each Guided Tour also includes a demo
project, with the demo project and the
step-by-step instructions in the Help files
displayed side-by-side. With the demo
project, users can practice the steps
explained in the Tour. The demo project
already contains all of the Function Blocks
required for performing the demonstrated
instructions from the Guided Tour, and users
have access to appropriate editors, which
are already opened for this purpose.
“Guided Tours” are closely linked with other
Help components. Individual steps are linked
not only with each other, but also with
relevant information in the normal Help files.
This makes it easier for users to explore the
topics addressed in even greater depth
if desired.
“Guided Tours” through
the tools help users get
started with
SoMachine Motion
38
Electronic Help Documentation >
PacDrive 3:
Electronic Documentation –
the paperless manual
The tools, particularly EPAS and ECAM,
offer comprehensive documentation for
users. This wide array of systematically
recorded information can be accessed by
keyword search, and provides
comprehensive technical background
information and instructions on using the
tool. Unlimited availability of the
“E-Documentation” makes it unnecessary to
keep a hardcopy manual next to the keyboard.
Schneider Electric’s SoMachine Motion tools
are largely intuitive in their operation. The
Help function for each tool provides answers
to more detailed questions on operation, or on
the technical and mathematical background
of the available functions. As with typical
Windows applications, the Help function can
be started with the click of a mouse.
EPAS E-Documentation offers two ways to
access information: via a table of contents
listing topics contained in the
E-Documentation…or, users can also use
the Index to search alphabetically for
available topics. A search algorithm limits
the content that is displayed.
Search via the Index:
The terms related to a
particular topic are listed in
alphabetical order;
the input field for keywords is
shown above the list
Search in
content directories:
Calling up help
information in EPAS
On-screen documentation is also available
for library Function Blocks, with technical
background, scope of functions,
parameterization, and integration of each
function described in detail. Integrated
hyperlinks in the explanations let users jump
to other sections of the documentation for
more detailed explanations of specific terms.
Documentation of library Function Blocks:
The image shows the table of contents and one page from the library Function
Block for implementing wrapping mechanisms with and without a dancer
39
PacDrive 3: Controllers
Scalable controller
performance
The PacDrive 3 LMC 101C, 201C, 300C, 400C, and 600C automation
controllers cover a wide range of applications. Variables including: the number
of axes to be synchronized, data transmission volumes, and the range of
robotic elements to be integrated – all determine which controller offers the
optimum balance of price and performance.
LMC x01C and x00C
Series controllers:
Scalable controller
performance for
cost-effective
automation solutions.
40
PacDrive 3: Controllers
A single platform for all
controller functionalities
PacDrive 3 LMC x01C and x00C controllers
provide scalable performance for
synchronizing up to 99 servo axes (at 1
msec network update rate for 99 axes), and
for up to 255 virtual axes. In addition to
motion functionality, all controllers combine
an integrated PLC, HMI, and IT
functionalities on a single hardware platform.
They are software-compatible, since each of
these controllers has identical Schneider
Electric Logic Motion Runtime software, and
users can program up to 4096 dynamic
electronic cam disks operating in parallel.
The program can switch between electronic
cam disks during operation, and control can
be distributed across a number of continuous,
periodic, or event-driven user tasks.
Each controller has two integrated cam
switch groups, each with 32 cam disks. The
system can allocate up to 254 cams, with up
to 32 different positioning or encoder signals
assigned to each of the two groups. Cam
signals can be routed to a memory cell or to
a digital output.
Functional:
The compact Flash
memory card behind
the display contains
all of the software that
needs to be transferred
when replacing the
controller
Depending upon the controller type, memory
can be up to 512 MB DDR2 RAM, or 128 or
256 KB NV RAM, with additional compact
Flash memory of 128 MB or more. The
memory card can be changed out without
removing the enclosure, as can the battery.
An alphanumeric display shows diagnostic
data, and the controllers include an
integrated eight-channel software
oscilloscope and a message logger for
diagnostics. All controller types are CE and
cULus certified.
A scalable controller
platform
One runtime software
All controllers are
software-compatible
Ethernet-based, fully
integrated automation
bus
Can control up to 99
real axes and another
255 virtual axes
Up to 254 SERCOS 3
nodes
1 msec network update
rate for 99 axes
Up to 4096 electronic
cam disks can be
switched during
operation
5 µsec for 1000 bit
instructions
Integrated plaintext
display for system
messages
Integrated software
oscilloscope and
message logger
Integrated I/Os – externally expandable
PacDrive 3 LMC x00C controllers can use
integrated, digital and analog I/Os to
communicate with a variety of sensors and
actuators directly, without being redirected
through field busses. Controllers include
both standard and high-speed I/Os (touch
probes) that allow significantly faster
responses to events (such as motionrelevant signals) recorded by sensors.
External I/Os can also be added.
41
PacDrive 3: Controllers
Interfaces and communication
SERCOS 3 is the PacDrive 3 automation bus
for servo drive and field communication, as
well as for safety communication*. Real-time
and standard Ethernet interfaces are also
standard. The standard Ethernet connection
serves as an interface to the engineering
system and the HMI via OPC, ARTI, or
Modbus™ TCP, and as an open interface for
customized communications solutions.
All Schneider Electric PacDrive controllers
also have a CANopen™ interface, and the
LMC x00C controllers have a PROFIBUS™
interface (master and slave) as well. In
addition to communication via SERCOS 3
and Ethernet, LMC x00C controllers can also
simultaneously communicate via two field
bus protocols and real-time Ethernet, e.g.
CAN and Profinet™. Optional expansion
cards are also available for all controllers to
implement additional field bus interfaces,
such as EtherNet/IP.
USB and serial interfaces are also standard
in all controllers. The serial interface can be
configured as an RS 232 or RS 485 interface.
Performance overview:
All LMC x01C and x00C Controller types
Controller type
PacDrive LMC
101C
201C
4
8
Availability
Motion Performance
PLC Performance
400C
600C
16
99
Immediately
Maximum number of synchronizable
axes/network update rate (1 msec)
8
Number of dynamic electronic cam
disks operating in parallel
4096
Time required per 1000 bit instructions
[µsec]
5
Programmable dynamic cams
254
Cam cycle time [µsec]
250
Number of user tasks, continuous,
periodic, or event-driven
Any number, within the system limits
Fast task network update rate [µsec]
250
Communication
Housing dimensions
300C
Integrated motion bus
SERCOS 3 interface
Integrated Ethernet connection
10/199 Base-T
10/100 Base-T
Number of integrated
field bus interfaces
1, CAN
2 (3), PROFIBUS DP, CAN oder EtherNet/IP
Number of optionally integrable
field bus interfaces
1
2, PROFIBUS DP, CAN oder EtherNet/IP
Width x Height x Depth [mm]
45 x 230 x 220
104 x 270 x 240
Subject to change without notice
* according to IEC 61508:1998, EN/ISO 13849-1: 2008
42
SERCOS 3
SERCOS 3
Automation Bus
SERCOS 3 is the universal automation bus for PacDrive 3.
Drive-based communication, I/O communication, and safety
communication* can be implemented using the same medium.
Cat5e
Baudrate: 100 Mbit/s
Cycle time: 1 ms to 4 ms
Vendor-neutral
Powerful
With IEC 61491, SERCOS established itself
as the worldwide communication standard
for automation. SERCOS 3 uses industrial
Ethernet for its transmission physics. More
than 50 controller manufacturers and 30
drive manufacturers worldwide support
the standard.
Greater bandwidth makes SERCOS 3 even
faster than SERCOS 2. This allows a
network update rate of 1 msec for up to 99
drives. An innovative synchronization
procedure makes SERCOS 3 even more
precise than before.
Universal
The use of standardized profiles for drive
technology, I/O, and communication between
controllers (C2C) increases the range of
possible applications for SERCOS 3. For the
first time, SERCOS can be used as a fully
integrated Ethernet-based solution for drive
and field bus communications, including
communications in safety automation*.
SERCOS 3 also permits parallel transmission
of standardized or proprietary IP protocols
over a non-real-time channel.
Bidirectional full-duplex
Ethernet communication
Media redundancy to
reduce failure probability
Simpler, more
cost-effective design
No hubs or switches
CAT5e cable is
generally sufficient
Complete setup via
software, including
assignment of
bus addresses
* according to IEC 61508:1998, EN/ISO 13849-1: 2008
43
PacDrive 3: Functional Safety
Safety functions* for the
entire machine
With Schneider Electric’s PacDrive 3 system, standard communication and
safety communication* are completely integrated, and SERCOS 3 is the
shared basis for communication. Components for safety* signal acquisition
and safety* dialog (page 72) can also be integrated into the safety solution*
using safety I/O components (page 46).
* according to IEC 61508:1998, EN/ISO 13849-1: 2008
44
PacDrive 3: Functional Safety
Ethernet, TCP/IP, OPC, FTP,
ftp, http,
HTTP, SMS, SMTP
PacDrive 3 LMC 101C, 201C, 300C, 400C, 600C
Logic Motion Controllers
Magelis™
HMI
IT/COM
Logic Motion
Safe Logic Controller*
SLC x00
Other field busses:
PROFIBUS™ DP, CANopen™,
EtherNet/IP, Profinet™ ,
Modbus™
SERCOS 3 + Integrated Safety*
Stand-alone
Servo Drives
LXM 52
TM5 I/O
LXM 62 Multi-axes Servo Drives
+ Power Supply + ILM 62 CM
Distribution
Box
TM7
Remote I/O
TM7
Remote I/O
SH
SH
Torque
Motor
Linear
Motor
ILM 62
Complete integration…
A safety protocol via SERCOS 3 enables the
complete integration of safety communication
into standard communication, without the
need for additional dedicated cabling or a
safety bus. Safety signals from data
acquisition or dialog devices are connected
through safety terminals or remote I/Os, while
a safety controller on the SERCOS 3 ring
permits programming of the safety functions.
Both standard safety functions and safety
functions enhanced in accordance with PLC
Open Safety definitions can be implemented
with the integrated solution.
Schneider Electric’s SoMachine™ Motion
Workbench is a programming tool for the
engineering functions. In addition to the
program editor, it also contains tools to set
the safety device parameters for functional
safety components (drives, I/O components).
Also, the Safe Logic Controller can be
programmed directly via the PacDrive
controller, which functions as a gateway.
Fully integrated safety solution
Reduced installation costs, no more dedicated cabling
Integrated Workbench tool for safety software in IEC 61131-3
Other classic designs based on hardwired
safety components can be implemented
as well. Please consult with your
Schneider Electric or Distributor representative
to determine which Preventa Machine Safety
products are best suited for your applications.
* according to IEC 61508:1998, EN/ISO 13849-1: 2008
45
PacDrive 3: I/O communication
Rapid I/O communication
via SERCOS 3
The new SERCOS 3 bus interface for the Schneider Electric universal TM5
I/O system lets you create I/O solutions for rapid communication. The TM5
product line offers a variety of products for designing your specific I/O solution
on the SERCOS 3 automation bus.
PacDrive 3 LMC 101C, 201C, 300C, 400C, 600C
Logic Motion Controllers
IT/COM
Safe Logic Controller*
SLC x00
TM5 Bus ...
TM5/SERCOS
distributed I/O island
Logic Motion
Flexible I/O design:
The TM5 I/O bus can connect
up to 25 additional remote units
to each I/O island, and can bridge
a distance of up to 100 m between
two remote units.
SERCOS 3 + Integrated Safety*
≥ 100 m ...
TM5/...
remote I/O island
≥ 100 m ...
TM7 IP67
Remote I/O
≥ 100 m ...
TM7 IP67
Remote I/O
≥ 100 m ...
TM5/...
remote I/O island
TM5/...
remote I/O island
... up to 2500 m
... up to 25 remote I/O islands
Flexible and modular
The modular TM5 I/O system is specifically
designed for creating distributed I/O
solutions on the SERCOS 3 automation bus.
I/O networks can be built with both line and
ring topologies.
the benefits of this design including rapid
assembly and a reduced need for spare
parts. Functional units that incorporate
digital/analog I/Os, mixed-function units,
and power supplies are also available.
One terminal block can include up to
250 individual modules, with the basic unit
of each I/O island being the SERCOS 3
interface, which is plugged into a bus base
module together with the first terminal.
Additional I/O modules can be snapped to
this unit.
The TM5 system provides additional
flexibility with the option to connect
additional remote terminal blocks to a
terminal block via the TM5 I/O bus at
distances of up to 100 m, using transmitter
and receiver units. Up to 25 of these remote
I/O units can be connected serially to a
terminal block via the TM5 bus, and in
extreme cases, the range can be extended
up to 2.5 km for a distributed I/O solution!
Each of these modules consists of three
basic components: bus base, function unit,
and one of the various terminal blocks, with
* according to IEC 61508:1998, EN/ISO 13849-1: 2008
46
PacDrive 3: I/O communication
Plug together
and snap in:
Components can be
combined to create
both the basis unit with
the SERCOS 3 interface,
as well as all additional
functional modules,
including safety modules*
Standardized and fast
Communication on the TM5 system
corresponds to that of SERCOS 3 I/O-Profil
V1.1.2. In addition to consolidation of drive
and I/O communication on a shared,
Ethernet-based medium, the primary
advantage of I/O communication via
SERCOS is its high transmission speed.
With network update rates of up to 1 ms,
the system can satisfy the most demanding
response time requirements.
Expandable with IP67
technology or safety terminals*
The TM5 technology in IP 20 is essential for
connecting the soon-to-be-released, highly
compact TM7 modules to a SERCOS
automation bus…and expanding the ability
of I/O systems to operate under harsh
environmental conditions. Safety
communication* versions of both TM5 and
TM7 modules are available, with special
coloring to clearly differentiate them from
standard technology. Standard and safety
I/O modules can be mixed.
Up to 30 % time savings
for assembly, cabling,
and commissioning
Compact technology,
small footprint
Decentralized I/O islands
via TM5 bus
TM7 modules for IP67
TM5 and TM7 modules
both available for safety
communication*
I/O islands in IP67:
The TM5 bus can be used
to connect TM7 modules
in both standard and
safety* designs
* according to IEC 61508:1998, EN/ISO 13849-1: 2008
47
PacDrive 3: Servo Drives, Multi-axis Solutions
Schneider Electric
Lexium™ Servo Drives:
Flexible configuration
and lower costs
The modular servo drives of the LXM 62 Series and the integrated ILM 62
drives reduce space requirements in the control cabinet and lower
costs, particularly for multi-axis applications. Stand-alone drives with an
integrated power supply will soon be available for servo drive solutions with
self-contained single axes. These drives will also be supplemented with
integrated stand-alone versions, as in the multi-axis design.
SERCOS 3 + Integrated Safety*
Flexible
servo drive design:
Control-cabinet-based
stand-alone or multiaxis servo drives are
supplemented with
integrated variants
Cabinet
Stand-alone Axes
Pos & Speed
Cabinet
Multi Axes
Pos & Speed
Integrated
Multi Axes
Pos & Speed
* according to IEC 61508:1998, EN/ISO 13849-1: 2008
48
PacDrive 3: Servo Drives, Multi-axis Solutions
Lexium™ LXM 62
Universal servo drives for multi-axis solutions
Schneider Electric’s fully digital servo drives
in the Lexium™ LXM 62 series are modular,
consisting of single drives (1 axis) and
double drives (2 axes) of equal size, as well
as power supplies with different output. All
single and double drives in a group use a
shared power supply. Multiple groups are
possible, with the number of axes being
limited by the type of Controller used.
All LXM 62 components offer easy handling
and installation, startup, and replacement.
The rapid, front side-connection to the power
supply automatically includes integration
into the DC bus as well. The motor and
encoder cables exit at the bottom of the unit,
leaving room for easy access at the front of
the device.
The Lexium LXM 62 series lets users
implement cost-effective compact multi-axis
solutions, with the double drives providing
particular advantages.
Integrated design:
Power supply and two
drive modules – each
half the width of the
power supply
49
PacDrive 3: Servo Drives, Multi-axis Solutions
Motor/encoder cables
exit at the bottom of
the unit:
Leaves room at the front
of the device for rapid
assembly/disassembly of
LXM-62 components
Connection to DC bus,
24 V power supply,
and ground wire:
Move the slide to the
left, tighten the screws,
and it’s done
Fast connection
to SERCOS:
Single and double
drives are integrated
into the SERCOS
ring with short cable
bridges.
Technical Data / Servo Drives
Type: LXM 62
DU60A
DD15A
Availability
DD27A
DxxxA
Immediately
Number of synchronizable
axes
2
5
9
Peak current Aeff
6
15
27
DD15B
2
22
50
2x2
2x5
2x9
45
100
2x6
2 x 15
2 x 27
Supply voltage [V]
Min. 250 V DC, max. 700 V DC
Supply frequency [Hz]
48 to 62
Control voltage [V]
DC 24 V (-20% / +25%)
SERCOS 3
Encoder
Hiperface (more available soon)
Inverter Enable
1 input
2 inputs
Digit. inputs
2
2x2
Digit. inputs or TP
2
2x2
Digit. inputs or
outputs
2
2x2
Housing dimensions
D x W x H [mm]
270 x 44 x 310
270 x 89 x 310
Protection rating
IP 20
Excess voltage category
K3, T2 (DIN VDE 0110)
Excess voltage resistance
–
Degree of radio interference
–
Certifications
CE, ULus
Subject to change without notice
DD27B
Immediately
1
Continuous current Aeff (4kHz)
Interfaces
DU60B
Pending
Motion bus
50
DD45A
270 x 44 x 310
PacDrive 3: Servo Drives, Multi-axis Solutions
More innovation from Schneider Electric…
Another innovation is that all servo drives are
coupled to the DC bus and to the power
supply: No backplane connections are
required, and the modules can be coupled to
the adjacent module with a front-side
quick-connect with stop screws in less than
two minutes.
LXM 62 Series servo drives can be used with
all PacDrive System motors, both rotary and
linear, and all servo drives have an electronic
name plate. Upon first use or exchange of
the device, it is identified by the centralized
controller and configured based upon the
specified parameters. The servo drives
themselves in turn detect connected motors
by their name plates.
When the connection is made, LEDs signal
proper power supply with the 24 V control
voltage. The design functions without any
additional effort, even when drives are taken
out and reinstalled from a continuously
connected series of devices.
LXM 62 servo drives can be integrated into
safety automation designs (in accordance
with IEC 61508:1998 SIL2, EN/ISO 138491:2008 PL d) by using the Inverter Enable
input (or two in the case of double drives).
Less space required in the control cabinet
Minimal assembly/
installation time
Tool-free motor connection
Optimized feedback
loops minimize
contouring errors
Safety input Inverter Enable (pursuant to IEC 61508:1998, EN/ISO 13849-1:2008)
for each axis
Automatic motor
detection
Software-compatible
with integrated servo drives ILM and with stand-alone servo drives
Technical Data / Power Supplies
Type: LXM 62
PD84A
Pxxxx
Availability
Immediately
Pending
Continuous current (A)
42
120
Peak current (A)
84
179
Continuous output [kW]
25
67
50
100
Peak output [kW]
Supply voltage [V]
3AC208V (- 10%) to 3AC480V (+8%)
Control voltage [V]
DC24V (-15% to +25%)
DC bus voltage [V]
DC250V to DC700V
SERCOS 3 interface
integrated
Bleeder
Integrated
Recovery planned
EMC-Filter
Integrated
External
Housing dimensions
D x W x H [mm]
270 x 89 x 310
270 x tbd x 310
Protection rating
IP 20
IP 20
Excess voltage category
K3, T2
(DIN VDE 0110)
–
Excess voltage
resistance
–
–
Degree of radio
interference
–
–
Certifications
CE, ULus
Subject to change without notice
51
PacDrive 3: Integrated Servo Drives
Lexium™ ILM 62
Multi-axis design for true plug-and-play
modular machine building
Plug-and-play solution…
Multi-axis design requires up to 90 % less control cabinet space
Different dimensions, with peak torques of up to 55 N•m
Can be combined with single and double drives to a shared power supply
70% shorter cable lengths
90% less wiring required in the control cabinet
50% less cable installation required on the machine frame
With quick interconnects and hybrid cables
for signal and power level, automatic network
configuration, and diagnostic functions…
Schneider Electric’s Lexium™ ILM 62 servo
modules with integrated drive electronics
are the technological successors to iSH
servo modules. With more functionality than
compact drives alone, this drive and network
combination together form a true plug-andplay solution combining mechanics,
electronics, and software.
Servo modules move servo drives out of the
control cabinet and into the field. iSH
technology reduces wiring and cabling
requirements in the control cabinet by up to
90%, with the only components remaining in
the control cabinet being the PacDrive
controller, the shared power supply for 40 or
more servo modules, and the CM
(connection module).
The CM feeds power to the ILM 62 servo
modules from the same power supplies as
the LXM 62. The components, which have
compatible dimensions, allow the
assignment of ILM servo modules to groups
with different safety functions*, for example.
* according to IEC 61508:1998, EN/ISO 13849-1: 2008
52
PacDrive 3: Integrated Servo Drives
Smaller control cabinets:
With intelligent servo
modules, the servo drives
are mounted in
the machine frame,
leaving only the
controller and the shared
power supply in the
control cabinet
Reduced costs…
shorter installation time
ILM servo modules use a flexible cabling
approach, consisting of pre-terminated
hybrid cables and distribution boxes…and
the network itself is configured as a plugand-play solution. Compared to conventional
servo solutions, this reduces the required
cabling by up to 70%, and the labor required
for installing the servo solution is reduced by
approximately 50%.
Schneider Electric ILM servo modules are
the key element in modular machine design.
They permit modular design of mechanics,
software, and even electronics. This makes
ILM servo modules an ideal solution for
machines with a variety of optional
mechatronic modules. Aside from any
additional power supply units required, any
later addition of modules to a machine
requires no changes in the control cabinet.
Peak torques of
3.5 to 55 N•m
ILM servo modules are planned in flange
sizes of 70, 100, and 140 mm. A 55 mm
flange will be available at a later date. This
will completely cover a holding torque range
of 1.1 to 12.5 N•m and/or a peak torque of
3.5 to 55 N•m.
The models are software-compatible with
one another and with LXM 62 and LXM 52
Series servo drives… and, additional options
include a holding brake, a feathered key
groove, and a multi-turn encoder with
electronic name plate. The addition of a shaft
seal can increase the protection rating from
IP40 to IP65.
53
PacDrive 3: Servo Drives for stand-alone Solutions…
Lexium™ LXM 52
Servo drives for compact applications
Compact design
High power density
Software compatible
with LXM 62 and ILM 62
In a conventional stand-alone design,
Schneider Electric’s Lexium™ LXM 52 Series
servo drives are particularly well suited for
economical configuration of servo drive
solutions with self-contained single axes.
They communicate via SERCOS 3 and are
interchangeable with the LXM 62 and ILM 62
Series without any programming changes.
The servo drives have electronic name
plates and can be automatically configured
by the controller upon initial commissioning
or following an exchange. They identify
connected servomotors based upon their
name plates and perform parameterization
based upon the program specifications.
Technical Data
Lexium™ LXM 52
servo drives
are ideal for applications
with a small number
of axes
Type
Lexium™ LXM 52
Availability
Pending
Number of synchronizable
axes
1
Continuous current (Aeff )
1,5
3
6
10
24
Peak current Aeff
6
9
18
30
72
Continuous output [kVA]
0,3
0,9
1,8
3
7
Supply voltage [V]
380 V (-15%) to 480 V (+10%) AC
Supply frequency [Hz]
48 to 62
Control voltage [V]
DC 24 V (-20% / +25%)
Motion bus
SERCOS 3
Housing dimensions
D x W x H [mm]
220 x 48 x 230
220 x 68 x 230
220 x 108 x 230
Protection rating
IP 20
Excess voltage category
KIII, T2 (DIN VDE 0110)
Excess voltage resistance
–
Degree of
radio interference
–
Certifications
CE, cULus (Pending)
Subject to change without notice
Lexium integrated stand-alone servo drive:
The integrated drive for compact applications
Stand-alone drives installed in control
cabinets are not the only option for
applications with a small number of axes.
Integrated drives are also available, just
as with multi-axis designs. With these
54
innovative integrated servo drives, the
required components for controlling and
powering a servo motor are combined into a
single assembly.
55
PacDrive 3: Servo Motors
Rotary and linear
servo motors
Modern, high-speed production machines require highly dynamic,
precise AC servo motors with a wide range of rated torques. Brushless,
overload-protected servo motors – with high resolution encoders as well as
torque and linear motors – provide solutions for a variety of applications.
All of the Schneider Electric servo motors shown below can be operated by
Lexium™ LXM 52 and LXM 62 servo drives, and integrated into synchronized
multi-axis systems on the SERCOS 3 interface.
Low inertia rotor:
Lexium SH Series
AC motors meet the
highest performance
requirements
56
PacDrive 3: Servo Motors
SH
Servo motors in five flange sizes
Schneider Electric SH motors are available in
five flange sizes – from 55 mm to 205 mm,
and a wide range of rated torques – and are
ideal for many applications. SH motors
deliver impressive dynamics because of their
low inertia compared to other servomotors.
They are exceptionally compact thanks to
salient pole winding technology, and the
sleek housing is equipped with plug
connectors that can be rotated 270°. The
electronic name plate makes these motors
an integral component of the PacDrive 3
automation system.
There are different options available for
including SH servo motors with customized
drive solutions, as all of the motors are
equipped with high-resolution, single-turn or
multi-turn absolute value encoders. Additional
shaft seals can be integrated for increased
protection of bearings, and these motors can
be adapted to harsh environmental conditions
with an optional IP67 kit.
Technical Data
Flange Size/
Length
Holding
torque
Ambient
cooling
Holding
torque
current
Ambient
cooling
Holding
torque
Fan
cooled*
Holding
torque
current
Fan
cooled*
Peak
torque
Rotor
inertial
load
Rated
speed
M0 [N•m]
I0 [A]
M0 [N•m]
I0 [A]
Mmax [N•m]
JM [kgcm²]
nN [min-1]
SH055/1
0,5
0,73
–
–
1,5
0,059
8000
SH055/2
0,8
1,2
–
–
2,5
0,096
8000
SH055/3
1,2
1,7
–
–
3,5
0,134
8000
SH070/1
1,4
1,8
–
–
3,5
0,25
6000
SH070/2
2,2
2,9
–
–
7,6
0,41
6000
SH070/3
3,1
4,1
–
–
11,3
0,58
6000
SH100/1
3,3
3,5
4,3
4,7
9,6
1,0
5000
SH100/2
5,8
4,8
7,5
6,3
18,3
2,31
4000
SH100/3
8,0
6,6
11,0
9,0
28,3
3,22
4000
SH100/4
10,0
6,2
14,2
8,9
40,5
4,22
3000
3000
SH140/1
11,1
7,8
15,6
11,0
27,0
7,41
SH140/2
19,5
13,2
30,8
21,6
60,1
12,68
3000
SH140/3
27,8
17,6
42,4
27,7
90,2
17,94
3000
SH140/4
33,4
21,3
54,8
33,6
131,9
23,0
3000
SH205/1
36,9
2,01
46,9
28,9
110,0
71,4
3000
SH205/2
64,9
25,7
87,2
37,3
220,0
129,0
2000
SH205/3
94,4
33,2
124,5
47,2
330,0
190,0
2000
Compact design and high power density thanks to salient pole windings
Low inertia rotor
Electronic name plate
Optional shaft seals,
integrated brakes
Triple overload capacity
Exterior fan cooling or
water cooling for better
capacity utilization
Optional IP 67 rating for harsh environmental conditions
Single-turn or multi-turn absolute value encoder
Subject to change without notice
57
PacDrive 3: Servo Motors
Direct drives
High precision with minimal wear
In contrast to conventional drive solutions,
rotary and linear direct drives generate
torque precisely where it is needed in the
machine. The absence of detours through
gears or belts allows the generation of
significant torque. It also reduces the space
requirements for drive components, and
eliminates parts that may be subject to
mechanical wear and tear. Benefits include
less maintenance and greater reliability.
Because of its superior dynamics when
compared with other drive solutions, direct
drive technology offers improved machine
performance in many cases.
Schneider Electric’s PacDrive 3 technology
can be used to integrate rotary and linear
direct drives into synchronized multi-axis
systems. Both motor types can be operated
with standard Lexium™ LXM 52 and Lexium
LXM 62 Series servo drives, even with
high-speed machines having demanding
synchronization requirements.
Direct drive technology
for PacDrive:
Lexium servo drives can
operate a wide range of
linear and torque motors
58
In contrast to standard servos, both direct
drive models generally require more precise
tuning and/or adaptation to a specific
application. Schneider Electric recommends
that you consult with our expert teams of
application engineers and motor specialists to
select suitable motor types for your machines.
If necessary, we can even provide assistance
on integrating the motors into your
application. This helps reduce risks when
getting started with direct drive technology.
Highly dynamic drives
Linear drives reduce wear and tear
Direct drives generally deliver high precision
Engineering support
available upon request
for drive selection and
application
59
PacDrive 3: Robotics Solutions
Integrated Robotics
Picture: Cavanna robotic division
The integration of robotics into the machine control solution is one of
the outstanding benefits of Schneider Electric’s PacDrive 3 automation
system. On the software side, the integration of robots is made
simpler by an IEC-compliant library with Equipment Modules (EMs)
and Application Function Blocks (AFBs) for motion programming
and transformation to all commonly used kinematics. Thanks to
the availability of complete robot arm mechanics, development of
customer-specific kinematics or integration of third-party products
is no longer necessary. This permits even faster creation of robotenabled machine designs.
60
PacDrive 3: Robotics Solutions
Integral automation architecture
The Schneider Electric PacDrive 3 system supports an almost unlimited variety of kinematic configurations, allowing
robotics to become an integral part of a machine‘s automation architecture. High-performance PacDrive 3 Controllers
are capable of synchronizing up to 99 axes in a real-time multi-axis system. From the controller perspective, a robot is
reduced to a motion control system with a corresponding number of servo axes, which can operate under demanding
real-time conditions. In this way, the controller can manage one or more robots in addition to other machine functions
within an IEC 61131-3-compliant program.
SoMachine™
Motion
Ethernet, TCP/IP, OPC, ftp, http, SMS, SMTP
PacDrive 3 LMC x00C
Logic Motion Controller
IT/COM
Integration of robots in
the automation architecture:
Depending upon the number of axes, kinematics,
speed, and other requirements, one PacDrive LMC
600 C controller, for example, can control between
six and 30 robots, each with three axes
Logic Motion
Safe Logic Controller*
SLC x00
SERCOS 3 + Integrated Safety
In/Out
Infeed
Dual Belt
Robot
Grouping
Easy software integration
thanks to AFB and EM libraries
One controller can The integration of robots into the PacDrive 3
control machines and automation solution software drastically
multiple robots
reduces the number of complex software
Software integration using Function Block algorithms needed for the solution. Robots
are mapped onto a software module, which
library
Integrated IEC is then inserted into modular, IEC-61131-3 61131-3-compliant compliant program structures, just like other
software, no additional mechatronic machine modules. This
programming tools
Easy access to process structure is based upon library Function
Blocks that are parameterized by the user or
parameters
One HMI concept for“fed“ with motion data in the form of a
machines and robots
program or a table. Once motion paths have
Transformation modules been defined, parameters can be specified
for popular robotic
in order to limit the acceleration forces that
kinematics such as act on the transported product. The option to
Gantry, Scara, Portal,
Articulated, Delta
specify blending parameters provides further
potential for optimizing the motion paths.
The controller performs all of the other
functions, including actuation of the robot
axes, based upon library Function Blocks.
Robot
Robot
Conveyor Belt
Cartoner
Transformation modules for
PacDrive 3 and standard kinematics
In the PacDrive robotics solution, motion
programming and its transformation to robot
kinematics are separate processes. This
means that the robot kinematics can be
selected independently of the generated
motion program. Regardless of whether the
project uses standard kinematics developed
by the customer, third-party suppliers, or
PacDrive mechanics – Delta-2, Delta-3,
gantry, and portal kinematics are currently
available – the appropriate transformation
module adapts the selected solution to the
motion program.
In principle, the available transformation
modules can be used to adapt all typical
2 to 6-axis systems.
* according to IEC 61508:1998, EN/ISO 13849-1: 2008
61
PacDrive 3: Robotics Solutions
Motion transformation:
Appropriate
transformation modules
incorporate all typical
kinematics into the
controller software,
whether it involves
PacDrive robotics or
customized kinematics
Delta 2
Delta 3
Gantry
Portal
Scara
Articulated
In addition to
transformation
modules mapped to
these kinematics, a
universal
transformation
module is also
available for
custom-designed
or third-party
kinematics, allowing
various robots
to be controlled
with PacDrive 3
Controllers
62
PacDrive:
Robotics Solutions
PacDrive P4
Complete robotics
packages for
Delta 3 kinematics
Everything fits together: Robot mechanics,
servo systems, and the robotics library
provide a ready-to-use solution. In addition,
complete packages, including engineering,
can accelerate the integration of robotics into
an application.
The P4 delta-3 robot from Schneider Electric,
featuring full stainless steel construction, is
designed for pick-and-place applications, as
the software includes a pre-programmed
interface for integration of the most commonly
encountered vision solution. The P4 can be
equipped with an optional rotational axis
(P4s-R), with the P4 robot arm being driven by
conventional motors with cabinet-mounted
servo drives (P4s-F or P4s-R) or by intelligent
servo modules with integrated control
electronics (P4i-F or P4i-R). Thanks to their IP
65 rated washdown configuration, the P4s-F
and the P4s-R are also suitable for hygienic
environments. The P4 is also available in
an ISO 14644-1-certified Class 6
cleanroom design.
P4 delta-3 robot
kinematics:
With standard motors,
available in washdown
configuration up to IP 65
Type
Load capacity
Max. speed
Max. acceleration at 1kg
Max. acceleration at 1.5kg
Number of axes
Repeatable position accuracy
Work envelope height
Work envelope diameter
Work envelope rotation*
Protection rating
P4s-F / P4s-R
P4i-F / P4i-R
1,5 [kg]*
10 [m/sec]
100 [m/sec2]
75 [m/sec2]
3 (4**)
+/- 0,1 [mm]
225 / 350 [mm]
1200 / 750 [mm]
Unlimited
IP 65
–
* up to a maximum of 3.5 kg with reduced acceleration
** including rotational axis in the R version
Subject to change without notice
63
PacDrive 3: Robotics Solutions
Linear Motion
Single and multi-axis systems for linear motion
Portal axes:
Left: PAS S (spindle
drive), center: PAS B
(timing belt drive), and
right: TAS linear table
Cantilever axes:
Left: CAS (round rod axis),
right: CAS 4x (profile axis)
MAX H two-axis system:
Designed for positioning
over long distances
MAX P linear positioner:
The combination of
double axis system and
cantilever axes can be
mounted both above and
below the workspace
64
The Schneider Electric modular linear
motion system consists of basic elements
and complete solutions for a variety of 1, 2,
and 3 dimensional motion tasks. Thanks to
its modular structure, the elements can be
configured as needed, with the length and
stroke of each axis system being
individually determined.
Portal axes in various sizes – with timing
belt drive or spindle drive as desired – can
move loads of up to 100 kg. The structural
elements of these linear tables are extremely
rigid, and the overall assembly has very
compact dimensions, with Cantilever axes
with round rods or a profile design being
particularly well suited for limited spaces.
Thanks to the fixed motor and moving body
of the axis, cantilever axes can move flexibly
into the work envelope.
MAX H Double-axis systems move loads
with great flexibility and speed across
distances of up to 5 1/2 meters. They also
serve as a basis for complete solutions
involving multi-dimensional motion tasks.
The MAX P linear positioner, a
combination of double-axis system and
cantilever axis, moves up to 50 kg with a
high level of precision.
PacDrive 3: Robotics Solutions
Mechanics packages
available for linear axes
up to three-axis portal
Compatible components
Support and service from a single source for the entire automation solution
Complete package of mechanics and engineering support available upon request
The MAX R portal robot with two servo
axes, and the MAX R 3 with three servo
axes, are the top-of-the-line designs for the
modular linear motion system. A rotational
axis can also be integrated as an option.
For models with up to five axes, PacDrive 3
offers pre-programmed or adaptable
transformation modules to integrate robotic
solutions into a machine’s program structure.
Portal robot
MAX R2 or R3:
This robot is used for
applications mounted
over the work envelope
as either an x-y or an
x-y-z unit, depending
upon requirements.
Technical Data
Single-axis systems
PAS B
PAS S
TAS
Portal axis
Portal axis
Linear table
Profile
Round rod
Profile
100
100
150
50
18
35
5500
3000
1500
1200
500
2400
8
1,25
1
5
2
5
Guides
Roller bearings/
ball bearings
Ball bearings
Recirculating
ball bearings
Roller bearings/
Recirculating ball
bearings
Recirculating ball
bearings
Roller bearings/
Recirculating ball
bearings
Version
–
–
–
Profile
Round rod
Profile
Timing belt
Spindle
Spindle
Timing belt
Timing belt
Design
max. load [kg]
max. stroke [mm]
Positioning speed [m/s]
Drive element
CAS
Cantilever
Telescoping axis
Double-axis and Multi-axis systems
MAX H
MAX S
MAX P
Double-axis system
Axes
MAX D
MAX R2
Linear positioner
MAX R3
Portal robot
1
1
2
2/2
2
3
max. load [kg]
250
300
50
2/5
137
50
max. stroke in x [mm]
5500
5500
5500
300/700
5500
5500
max. stroke in y [mm]
–
–
–
–
1500
1500
max. stroke in z [mm]
–
–
1200
150/300
–
1200
Subject to change without notice
65
PacDrive 3: Human/Machine Interfaces
Operator interfaces
with display panels
from 3.8" to 19"
The variety of product sizes provided by Schneider Electric’s Magelis™ HMI
program – with its Small and Advanced Panels – opens up a wide range of
HMI design possibilities. An ARTI driver simplifies the engineering phase for
integrating PacDrive 3 solutions, by providing direct access to the runtime
system variables.
The right size
for the right display:
Magelis HMI panels
allow users to create
customized solutions with
less engineering time
66
PacDrive 3: Human/Machine Interfaces
Hardware variety
Depending upon the model,
Schneider Electric’s Magelis™ HMI systems
are available in display sizes ranging from
3.8" to 19", with different hardware features
opening up possibilities for individual
applications. Touchscreen panels with
VxWorks, Windows® XP, or XP embedded
are available for standard operating
systems, and solutions with separate display
monitors and their associated hardware, or
handheld devices offer still more alternatives.
Flexible configurations with application
memory and/or memory cards for flexible
memory expansion – as well as a variety of
interfaces – make it easy to integrate display
panels into your applications.
Easy connection:
Magelis HMI display
panels include most
popular interfaces
Efficient Engineering
Schneider Electric’s Vijeo Designer™
configuration software can be used to
uniformly implement PacDrive 3 Magelisbased HMI solutions. An ARTI protocol driver
reduces engineering time by building a
bridge directly from the configuration tools to
the controller application, providing direct
access to runtime system variables, which
can then be easily browsed using the
configuration tool. The “otherwise typical,
additional definition” of variables for the HMI
application is no longer required.
Touchpanels, keyboard entry devices
Detachable solutions and handheld devices
Different operating systems
Optimal integration into PacDrive 3 solutions with ARTI drivers
Magelis HMI
Ethernet, TCP/IP
Vijeo Designer
PacDrive 3 LMC 101C, 201C, 300C, 400C, 600C
Logic Motion Controllers
IT/COM
Logic Motion
Direct access:
An ARTI protocol driver
is the basis for highspeed communications
between the HMI panel
and the controller, with
access to the runtime
system variables
67
PacDrive 3: Field Bus Devices
Automation components
on the field bus
As an alternative to integrated Ethernet-based communication,
Schneider Electric’s PacDrive 3 system also offers dual-track designs
for conventional field buses. In this case, SERCOS 3 is the bus for
communication with the servo drives, and field devices can be integrated
into the automation solution via CAN, PROFIBUS™ DP, or other field bus
standards. Positioning solutions, variable frequency drives – and motor
protection components communicating via field bus – supplement the
automation solution to meet specific application needs. With PROFIBUS,
CANopen™ and DeviceNet™ connections, the range of products covers all
standard IP 20 and IP 67 rated I/O configurations.
68
PacDrive: Field Bus Devices
Lexium™ ILx
Integrated Positioning Drives
Schneider Electric’s Lexium™ line of integrated drives combines the motor, positioning
control, power electronics, field bus, and the “Safe Torque Off” safety* function in a single
assembly. Three product options are available:
The Lexium ILA, with a servo motor, delivers
a high degree of dynamics. It generates high
torque even during acceleration. Different
winding types are available for applicationspecific requirements.
The Lexium ILE, with an electronically
commutated motor, offers a high degree of
flexibility. The 3-phase synchronous
electronically commutated brushless DC
motor has a high holding torque of up to 8
N•m (with spur gear drive), often eliminating
the need for a holding brake. The integrated
electronics communicate absolute position
to the automation controller.
The Lexium ILS, with a step motor, is the
most precise of the three. The 3-phase step
motor generates high torque at low speeds
– often eliminating the need for a gear
reduction – permitting space saving direct
drive solutions. The Lexium ILS is the
solution for high resolution positioning with
good synchronization. Commissioning
involves little effort – the user merely needs
to adjust the power supply.
40% less wiring required
25% less cabling required
Flexibility thanks to
three possible motor technologies
Can be used with popular field buses
Simple installation and commissioning
Integrated safety* thanks to
safety* function
Safe Torque off (STO) pursuant to IEC/EN 61800-5-2
All integrated Lexium drives can
communicate via CAN, EtherNet/IP, or
PROFIBUS™ DP.
Lexium
integrated drives:
Three product options
with three different
motors
Technical Data
Speed range
[rpm] (direct
drive)
Continuous
torque (direct
drive)
Peak torque
(direct drive)
[1/min]
[N•m]
[N•m]
ILA servo motor
drive
< 7500
< 0,26
ILE EC motor drive
< 5000
ILS step motor drive
< 2000
Motor
Encoder
Holding
brake
Optional gearing
< 1,62
High-resolution
encoder (16384
increments)
Yes
Planetary gear unit
(Gear ratios from
3:1 to 40:1)
< 0,24
< 0,80
Hall sensors
No
Cylindrical and
planetary gear unit
(Gear ratios from
18:1 to 115:1)
<6
<6
With or without
index pulse encoder
(optional)
Yes
Planetary gear unit
(Gear ratios from
3:1 to 8:1)
Subject to change without notice
* according to IEC 61508:1998, EN/ISO 13849-1: 2008
69
PacDrive 3: Field Bus Devices
Altivar™ 312/32/71
Variable frequency drives
Schneider Electric’s Altivar™ family of variable frequency drives offers the right drive speed
controller for different applications. Like the Altivar 32, the Altivar 312 is appropriate for simple
machines with a power range of up to 15 kW. For more complex machines with higher
performance, the Altivar 71 with its power range of 0.37 to 1300 kW is the right solution.
Altivar:
Variable frequency
drives for both simple
and complex machines;
pictured are the ATV
312, 32, and 71 models
Altivar 312
Altivar 32
The Altivar 312, 32, and 71 series are well
suited for areas such as packaging,
transportation, conveyors, positioning
systems, or textile machines. This makes
them ideal for PacDrive 3 automation
solutions. Time-saving Function Blocks –
for integrating these frequency drives – are
provided in the PacDrive software library.
Altivar 71
All models can communicate via Modbus™
or CANopen™, and all can be connected to
PROFIBUS™, Ethernet IP, and DeviceNet™
through integrated communication cards.
Versions with connection via SERCOS 3
are pending.
Wide performance range
Integrates easily into PacDrive 3 solutions
CANopen integrated,
additional field bus
options available
for ATV 71 and 32
Technical Data
Altivar type
Power range in kW
(50 to 60 Hz power supply)
Output frequency in Hz
Short-term overload
moment in % of the rated
motor moment
Subject to change without notice
70
ATV 312
ATV 32
ATV 71
Single-phase
200 to 240 V
0,18 to 2,2
0,18 to 2,2
0,37 to 5,5
3-phase 200 to 240 V
0,18 to 15
0,18 to 15
0,37 to 75
3-phase 380 to 480 V
–
–
0,75 to 1300
3-phase 380 to 500 V
0,37 to 15
0,37 to 15
–
3-phase 525 to 600 V
0,75 to 15
–
–
3-phase 500 to 690 V
–
–
2,2 to 2000
–
0,5 to 500
0,1 to 599
1 to 1600 Hz to 37 kW,
1 to 500 Hz from
45 to 500 kW
for 2 s
200
200
220
for 60 s
170
170
170
PacDrive 3: Field Bus Devices
Lexium™ SD3 28
Step motors on the field bus
The Schneider Electric Lexium™ SD3 28 step motor drive is a powerful positioning solution
for communication via PROFIBUS™, CAN, and CANopen™. The different product options
are designed for holding torques of 1.7 to 19.7 N•m, with the safety function “Safe Torque
Off” (STO pursuant to IEC 61800-5-2) already integrated with the device. These drives are
available for up to 6.8 A, with the SD3 28 being suitable for a power supply with 1~115 VAC
and 230 VAC (50/60 Hz). A power filter is integrated, and the current is reduced automatically
at zero speed. The SD3 28 can also be equipped with motion monitoring on request.
Lexium SD3 28
step motor drives:
Compact plug-and-play
solutions with minimal
space requirements in
the control cabinet
Technical Data
3-phase step motor
Step motor drive
115 V/230 V
Holding torque at
zero speed
Maximum torque
Maximum
speed (RPM)
Type
[N•m]
[N•m]
[1/min]
Type
BRS368Wx
1,7
1,5
2000
BRS397Wx
2,3
2,0
2000
BRS39AWx
SD3 28 x U25 (2,5 A)
BRS39BWx
BRS3ACWx
BRS3ADWx
SD3 28 x U68 (6,8 A)
4,5
4,0
2000
6,8
6,0
2000
13,5
12,0
2000
19,7
16,5
2000
Plug-and-play without encoder systems and commissioning software.
Excellent synchronization
High torque even at low rotational speeds
Integrated safety functionality (STO)*
Subject to change without notice
* according to IEC 61508:1998, EN/ISO 13849-1: 2008
71
PacDrive 3: Electrical Components
Recording, notification,
power distribution
and switching
Schneider Electric manufactures an extensive product line of electrical
equipment for machine construction, production lines, and entire production
facilities, including: Power supplies, mounting and cabling systems for
low voltage and medium voltage applications, and control and signaling
equipment. The following excerpt from our product portfolio demonstrates
the wide variety of solutions we offer. Together, they can provide you with the
tools necessary for your particular needs and your specific solutions.
TeSys™ U
Motor starter:
Space-saving combination
of short-circuit protection
disconnect switch,
overload relay, and
contactor, with modular
design for greater flexibility
Safety signal recording*
with Preventa™:
Light curtains, switches,
switch mats, and many
other components trigger
safety responses in a wide
variety of situations
Safety dialog*
with Preventa:
With pullcord emergency
switches, emergency
stop buttons, enabling
switches, foot switches,
and two-hand control
units, this program
includes all of the
popular solutions for
safety-related command
and signaling devices
* according to IEC 61508:1998, EN/ISO 13849-1: 2008
72
PacDrive 3: Electrical Components
Harmony™ control and
signaling devices:
Signaling technology
as well as a series of
lighted and unlighted
pushbuttons, switches,
and much more
GV3 motor
starter and protector:
Triggers at motor currents of 9
to 65 A, with thermomagnetic
or magnetic triggers if needed
Altistart™ 01 and 48:
Soft starters for AC
induction motors
and three-phase AC
induction motors for
0.18 to 630 kW. Ideal
for use in combination
with Altivar™ ATV 312
and ATV 71 frequency
converters
OsiSense™ XG:
Open and extremely
compact RFID system
for all popular ISO data
media based on the
13.56 MHz standard
Control cabinets
and enclosures:
Wide range of sizes,
materials, and installation
accessories
OsiSense - Recording
systems and sensors:
A complete range of
sensors – optoelectronic,
inductive, or ultrasound
recording as well as
positioning switches
– for most industrial
automation applications
73
PacDrive 3 vs. the Competition
Compare
for yourself
The complexity of power automation systems and the number of individual
factors involved often make it difficult to directly compare one system
with another. Use our checklist on page 75 to identify the benefits of the
Schneider Electric PacDrive 3 system…then compare these with what our
competitors offer.
74
PacDrive 3 vs. the Competition
User benefit
PacDrive 3
International
assistance available
International assistance is standard at Schneider Electric, one of the world’s largest
suppliers of automation technology and electrical equipment.
Complete solutions from a
single source
Complete automation solutions, electrical equipment, installation, mechatronics, SCADA and
MES systems
Support
24/7 Help Line
Open standards
Programming design is IEC 61131-3 compliant. IEC standards for field bus communication,
international IT standards for vertical integration or remote maintenance
Sustainability
PC Intel platform, long-term availability of controllers, drives, and motors
Universal controller functionality
of the hardware platform
PLC, motion, and IT functionality, no additional and/or proprietary controller hardware
required for the complete machine (incl. robotics)
Scalability
Up to 99 servo drives, software can be ported between platforms
Ethernet-based automation bus
SERCOS 3, manufacturer-neutral and IEC standard
Diagnostic functionalities
Up to motor shaft thanks to electronic name plates in motors and drives, and message loggers.
Software oscilloscope for simultaneous display of PLC and motion variables
Simulation
Programs can be tested without real axes by using centralized controller architecture
Flexible design of servo drive
architectures
Stand-alone servo drives, multi-axis system with single/double drives and shared power
supply. Servo drives with integrated controllers to be released soon
Broad range of servo motors
High-performance standard motors, torque motors, and linear drives for a wide range
of torque
Safety design*
Standard solution available, integrated solution with safety PLC*.
Safety communication and safety I/Os* via SERCOS 3 to be released soon
Rapid installation and
commissioning
Plug-and-play technology thanks to electronic name plates in servo system components.
Hot-plugging of components on motion bus, extensive use of plug connectors
Remote maintenance
Remote maintenance via IP connection and diagnostic tools
Integrated tool design
Complete workbench with tools for the entire engineering process…for functional safety*,
commissioning and diagnosis, central database, and multiuser design for simultaneous
work on projects
Tool for motion design
Graphic motion design, drivetrain design, and power supply analysis in a single tool.
VDI motion rules available
Machine diagnostics
Software tool diagnostics integrated into SoMachine Motion Workbench. Can also be used
separately from Workbench (available free of charge).
Support of modular machine
designs
Programming tools completely designed for modular program structures. Standardized
software structures with optional use of the PacDrive programming template (Machine Pilot)
Function Blocks for creating the
machine program
PacDrive Libraries with AFBs for basic motion, PLC, cam disk, and technology functions,
mathematical functions, torque handling, dual-belt and multi-belt mechanisms, infeed,
HMI applications, simulation and testing (ETest), etc.
Function Blocks for program
standardization
PacDrive Libraries with AFBs for ANSI/ISA S88 Technical Report (OMAC/PackML),
Weihenstephan standard, and FDA…as well as operating mode, error and error response
management, process control, and pre-defined commissioning screens.
Function Blocks at the
machine/machine module level
Operating modes, error and error reaction management, process control, predefined
commissioning resources in the HMI
Hardware and software
integration of robotics
in machines
Robots are controlled by the machine‘s centralized PacDrive 3 Controller, requiring no
additional controller hardware. Software integration with IEC 61131-3-compliant library
Function Blocks for path generation, path optimization, transformation to all popular
kinematics…as well as synchronization with conveyor belts, products, and other robots.
Robots
Complete robotics kinematics packages are available, including drives, electronics,
and software
75
http://www.schneider-electric.us/
Schneider Electric USA, Inc.
8001 Knightdale Blvd.
Knightdale, NC 27545
USA Customer Care Center
Tel: 888-778-2733
Schneider Electric Canada
5985 McLaughlin Rd.
Missassauga, Ontario, Canada L5R 1B8
Canada Customer Care Center
Tel: 800-565-6699
The information and dimensions in this catalog are provided for the convenience of our
customers. While this information is believed to be accurate, Schneider Electric
reserves the right to make updates and changes without prior notification and assumes
no liability for any errors or omissions.
Altistart, Altivar, CANopen, Citect, Designer, DeviceNet, Harmony, Historian, Lexium,
MachineStruxure, Magelis, Modbus, Modicon, OsiSense, PlantStruxure, Preventa,
PROFIBUS, Profinet, SoMachine, TeSys, Vijeo, Schneider Electric and logo, and
“Make the most of your energy” are trademarks or registered trademarks of
Schneider Electric or its affiliates in the United States and other countries. Other
trademarks used herein are the property of their respective owners.
Design: Schneider Electric
Photos: Schneider Electric
VM08141-001EN-US
© 2012 Schneider Electric. All rights reserved.
05/2012
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